As global demand for high-quality stainless steel continues to grow, Walsin Lihwa executed a bold strategy to expand capacity, improve product quality, and strengthen its global footprint by expanding its capabilities in long products at its Yantai facility. To support this vision, Primetals Technologies supplied a modern bar and wire rod combination mill, enabling highly efficient stainless steel production while preparing the operation for future process innovations.
Challenge
Challenge
Walsin Lihwa's growth strategy included scaling production while expanding its product portfolio and global reach. To support increasing demand for high-quality stainless steel across Asia, the company needed to significantly increase production capacity while maintaining operational efficiency and controlling costs. At the same time, the company sought to improve dimensional tolerances and surface quality to serve more demanding applications while reducing downstream processing requirements that add unnecessary cost and complexity.
The goal was to achieve a flexible production line capable of supporting future expansion, new product opportunities, and continued technological innovation.
Solution
Solution
Primetals Technologies delivered a fully integrated, high-performance solution designed to meet both current and future needs.
Flexible Production
The combination bar and wire rod mill was designed to provide exceptional production flexibility, enabling Walsin Lihwa to manufacture a broad range of stainless-steel products from a single platform. The facility produces straight bar products ranging from 40-130 mm, bar-in-coil products from 18-40 mm, and wire rod products ranging from 5.5 - 18 mm. This extensive product range allows the company to quickly respond to changing market demands while maximizing utilization of the mill's production assets.
Advanced Process Technologies
Modern process technologies play a key role in improving both efficiency and product quality. The mill incorporates in-line quenching capabilities, reducing or in some cases eliminating the need for post-processing annealing. Additionally, the mill was engineered with future integration of direct solution treatment (DST) technology in mind, creating a pathway for additional process optimization. By reducing downstream processing and material handling requirements, these technologies help streamline production while lowering operating costs.
High-Precision Rolling and Finishing
The mill includes next-generation breakdown, roughing, and intermediate rolling stands, complemented by Morgan No-Twist Mill technology and advanced the Rod Reducing/Sizing Mill to achieve the high-quality standards required for premium stainless-steel products. Modern high-speed shears and coil handling equipment further enhance productivity and product consistency, ensuring precise dimensional control throughout the rolling process.
Intelligent Cooling and Handling
The solution also includes advanced cooling and material handling systems, supporting a wide range of product grades and quality requirements. Rapid transfer systems move material efficiently to optimized cooling solutions, while dedicated slow-cooling bins provide controlled cooling conditions for specialized grades. Together, these technologies enable tighter tolerances and improved surface quality, reducing the need for peeling after pickling and lowering overall production costs.
Digitalization and Automation
The mill's digital foundation is built on advanced mechatronic systems providing comprehensive production process control. Integrated Level 1 and Level 2 automation systems work alongside the Long Rolling Process Expert platform to optimize production performance and ensure consistent execution.
Combined with advanced quality control and production optimization tools, these systems enable data-driven decision-making, improved process stability, and consistently high product quality.
Close-up of the Morgan High Speed Laying Head as coiled stainless steel bar is exiting onto the cooling conveyor.
Results
Results
The new combination mill significantly expanded Walsin Lihwa's production capabilities, supporting annual output of up to 420,000 tons of stainless steel and nickel alloy products. The investment delivered measurable product quality improvements, including tighter dimensional tolerances, superior finishes, and greater consistency across the mill's diverse product portfolio. These enhancements enable Walsin to better serve customers with critical quality and reliability requirements.
Operational efficiency improvements helped reduce overall production costs throughout the manufacturing process. Lower material removal requirements during post-processing, reducing annealing needs through in-line process technologies, and a more streamlined production flow collectively contributed to improved cost competitiveness.
With the ability to produce multiple bar and rod products on a single line, the company can now quickly adapt production schedules and product mixes in response to changing customer and market requirements. A future-ready design for additional in-line processing technologies will ensure long-term operational growth.
A lineup of coiled bar on compactors waiting to be tied.
Benefits
- Expanded the company's product offerings, opening access to new markets
- Delivered measurable product quality improvements, such as tighter dimensional tolerances and greater consistency
- Reduced overall production costs
- Greater adaptability to changing customer and market requirements, thanks to the ability to produce multiple bar and wire rod products on a single line
Conclusion
This new bar and wire rod combination mill showcases how modern technologies can help a bar and wire rod producer expand into markets with higher quality requirements. These future-ready solutions:
- Boost operational efficiency
- Reduce production costs
- Improve product quality with tighter dimensional tolerances, superior finishes, and greater consistency
- Enable expansion into markets with higher quality requirements
